NBEAA Open Source Electric Vehicle Program
State-of-the-Art Electric Vehicle Conversion Task List
Updated May 18, 2010

Legend:
staff = SRJC administrative staff
faculty = SRJC faculty
class = SRJC DET 190, 191 or 193 EV or Alt Fuel class students, led by faculty
NBEAA = volunteer NBEAA engineering, technician and technical writer members, as assistants to SRJC faculty

Completed Fall 2009:

Status Task Number Owner Description
done 1 admin Obtain donor car
done 2 class Weigh car
done 3 class Remove ICE components
done 4 class Reweigh car and components removed, and create spreadsheet with EV weight estimate
done 5 NBEAA with faculty and class Design motor to transaxle adapter

Completed Spring 2010:

Status Task Number Owner Description
done 6 admin Obtain EV components
done 7 Make Mine Electric Fabricate motor to transaxle adapter
done 8 class Assemble motor, transaxle and adapter
done 9 NBEAA with faculty and class Designed mid and rear battery box and fabricated mid battery box
done 10 NBEAA with faculty and class Designed motor mount and front battery box

To be Completed Summer 2010:

Status Task Number Owner Description
  11 Drive Line Shop (tentative) Lengthen motor side half shaft
  12 NBEAA with faculty Design and post the following fabrication drawings:
- update motor mount with more dimensions
- mid battery box mount hole locations
- trunk floor modifications
- power electronics tray
- power brake mount
- power steering mount
- heater mount
in process 13 class Fabricate motor mount and front battery box
  14 class Drill under seat and mount mid battery box
  15 class Cut out spare tire well, install new trunk floor with spare tire hold down mount, fabricate rear battery box
  16 class Install traction batteries
  17 class Fabricate power electronics tray frame
  18 class Fabricate and install power brake mount
  19 class Fabricate and install power steering mount
  20 class Fabricate and install heater mount
  21 NBEAA with faculty Design and post the following wiring documents:
- block diagram
- battery interconnects and fuse mounts
- front, mid and rear battery box wiring diagrams
- junction box fabrication and wiring diagrams
- console fabrication and wiring diagrams
- low voltage wiring loom
- verification procedure

To be Completed Fall 2010 by November 24:

Status Task Number Owner Description
  22 class fabricate battery interconnects and fuse mounts, then install them along with BMS cell boards
  23 class fabricate, assemble and install junction box and power electronics tray plate, then install components on tray assembly
  24 class fabricate, assemble and install console
  25 class fabricate, assemble and install low voltage wire loom and attach to accessory battery
  26 class Verify charge operation
  27 class Verify power brake, power steering and drive operations
  28 staff Obtain registration tags, with SRJC smog referee change to electric fuel type
  29 staff Obtain insurance, with EV safety inspection and adequate coverage for added EV component value
  30 faculty and staff Drive to Moscone Center to show car at the AAA booth at the San Francisco International Auto Show, 57 miles one way, using public Avcon chargers on November 25, 2010

To be Completed by December 31, 2010:

Status Task Number Owner Description
  31 NBEAA with faculty and class Design, fabricate and install EV component splash and safety shields
  32 NBEAA with faculty and class Design, fabricate and assemble conduit assembly
  33 NBEAA with faculty and class Design, fabricate and install AC inlet
  34   Select and install forward and reverse claxons
  35   Add high voltage warning signs
  36 class reweigh vehicle and update weight spreadsheet
  37 Admin Paint logos on car: AAA, SRJC, EAA, Make Mine Electric, EV Components and EV Source
  38 class take additional pictures and measurements as required for manual; may require disassembly but car should be designed for ease of service and it is good experience for new students
  39 NBEAA Create conversion, maintenance and repair manual and post on NBEAA website